Ribbed film structures with pigment created visual characteristics

Abstract

In one example embodiment, a film includes a coextruded structure having both an extruded ribbed skin layer that includes a plurality of ribs, and a core layer. The ribs are spaced apart by a web that is integral with the ribs. The film also includes a coloring agent that is substantially more apparent in the ribs than in the web, such that a contrast in color and/or color intensity between the ribs and the web is visible.

What is claimed is: 
     
       1. A method for producing a film, comprising:
 adding a coloring agent to a first thermoplastic material to form a first thermoplastic resin; 
 coextruding the first thermoplastic resin into a first layer of a coextruded film and a second thermoplastic resin of the first thermoplastic material to form into a second layer of the coextruded film that abuts the skin first layer; 
 forming, during coextruding, a plurality of extruded ribs into the coextruded film that are spaced apart from each other by thinner portions that are integral with the extruded ribs such that:
 the extruded ribs of the coextruded film have a color of the coloring agent; and 
 the thinner portions of the coextruded film have a different color than the color of the coloring agent. 
 
 
     
     
       2. The method of  claim 1 , wherein adding the coloring agent comprises adding an opaque pigment. 
     
     
       3. The method of  claim 1 , wherein adding the coloring agent comprises adding a black pigment. 
     
     
       4. The method of  claim 1 , wherein further comprising coextruding the first thermoplastic resin into a third layer on an opposing side of the second layer as the first layer. 
     
     
       5. The method of  claim 1 , wherein:
 the extruded ribs of the coextruded film are opaque; and 
 the thinner portions of the coextruded film are translucent and appear colorless. 
 
     
     
       6. The method of  claim 1 , further comprising performing post-extrusion processing on the coextruded film, wherein the post-extrusion processing comprises one or more of MD stretching, MD ring rolling, TD stretching, or TD ring rolling. 
     
     
       7. The method of  claim 6 , wherein the performing the post-extrusion processing comprising causes a portion of the extruded ribs to change in one or more of color or color intensity. 
     
     
       8. The method of  claim 6 , wherein the performing the post-extrusion processing comprising forming a plurality of intermittent compressions extending long each of the extruded ribs. 
     
     
       9. The method of  claim 8 , wherein forming the plurality of intermittent compressions extending long each of the extruded ribs comprises forming intermittent compressing that differ in color from portions of the extruded ribs that are not compressed. 
     
     
       10. The method of  claim 8 , wherein forming the plurality of intermittent compressions extending long each of the extruded ribs comprises creating intersections of compressions and extruded ribs that provide the extruded ribs with a stitched appearance. 
     
     
       11. A method for producing a film, comprising:
 adding a coloring agent to a first thermoplastic material to form a first thermoplastic resin; 
 coextruding the first thermoplastic resin into a first layer of a coextruded film and a second thermoplastic resin of the first thermoplastic material into a second layer of the coextruded film that abuts the first layer; 
 forming, during coextruding, a plurality of extruded ribs into the coextruded film that are spaced apart from each other by thinner portions that are integral with the extruded ribs, the plurality of extruded ribs extending in a first direction, wherein the extruded ribs of the coextruded film have a color of the coloring agent and the thinner portions of the coextruded film have a different color than the color of the coloring agent; and 
 performing post-extrusion processing on the coextruded film to form a plurality of compressions extending across the co-extruded film in a second direction that is perpendicular to the first direction, the plurality of compressions intersecting with the plurality of extruded ribs, wherein intersections of compressions and extruded ribs provide the extruded ribs with a stitched appearance due to the non-intersecting portions of the extruded ribs having the color of the coloring agent and the intersecting portions of the extruded ribs having another color that differs from the color of the coloring agent. 
 
     
     
       12. The method of  claim 11 , wherein the second thermoplastic resin is devoid of coloring agents. 
     
     
       13. The method of  claim 12 , wherein the different color of the thinner portions differs from the another color of the intersecting portions of the extruded ribs. 
     
     
       14. A method for producing a film, comprising:
 adding a coloring agent to a first thermoplastic material to form a first thermoplastic resin; 
 coextruding the first thermoplastic resin into a core layer of a coextruded film and a second thermoplastic resin of the first thermoplastic material into a first and second skin layers of the coextruded film; 
 forming, during coextruding, a plurality of extruded ribs into the coextruded film that are spaced apart from each other by thinner portions that are integral with the extruded ribs such that:
 the extruded ribs of the coextruded film have a color of the coloring agent; and 
 the thinner portions of the coextruded film have a different color than the color of the coloring agent. 
 
 
     
     
       15. The method of  claim 14 , wherein adding the coloring agent comprises adding an opaque pigment. 
     
     
       16. The method of  claim 14 , wherein adding the coloring agent comprises adding a black pigment. 
     
     
       17. The method of  claim 14 , wherein adding the coloring agent comprises adding the coloring agent to the first thermoplastic resin and not the second thermoplastic resin. 
     
     
       18. The method of  claim 17 , wherein:
 the extruded ribs of the coextruded film are opaque; and 
 the thinner portions of the coextruded film are translucent and appear colorless. 
 
     
     
       19. The method of  claim 14 , wherein the coloring agent is apparent substantially only in the extruded ribs. 
     
     
       20. The method of  claim 14 , wherein there is a visible contrast between the extruded ribs and the thinner portions, and the visible contrast is at least one of: a contrast in color or a contrast in intensity of color.